Hello, pellet pals. Kind of a long post.. I've been having intermittent issues with my newer P38 for a while now. For the first couple months, everything was fine, then one day I noticed it making a repetitive clunking noise. I got under there and watched the bearing ride around the actuator arm. When the bearing first touched the arm, it clunked slightly. When it came off the arm, it clunked considerably. I only had maybe 35 bags through it at that time. I went to my dealer who recommended I clean the fines box and gave me a modified slide plate to try. The modification was the slight lip at the end of the feed plate was hammered flat and it was reduced in length very slightly to accommodate for the additional length gained from straightening the angle. His thought was the ramp on the end of the plate was causing fines to be forced under the plate, causing increased resistance. I took it home, cleaned out the hopper and fines box and tapped around the hopper and actuator arm area to see if anything was lodged in there. Before swapping the slide plates, I put the fines box cover back on and the noise was gone completely. The bearing rolled over the arm perfectly. Hmmm. I must have knocked some krap loose in there. Finished the end of the heating season without incident. Now this season, 1 month in, clunking. I repeated the cleaning/tapping process and quickly remedied the issue. Another 50 bags or so later, more clunking. I remedied it once again. I decided to go to the dealer again. Talked to one of the other owners. He recommended removing the deflector plate in the fines box. I thought he claimed it just made the newer style (smaller) fines box more cramped and more apt to have issues...like I'm having. He showed me on a demo assembly. Looked easy enough but I figured I'd wait to see if it does it again, which of course it did. Repeated my procedure AGAIN and fixed it....for 1 bag. While I was under there, I attempted to remove the deflector plate. Wasn't happening, not at the angle I was at anyway. Here I am listening to this thing clunk again and hoping one of you guys/gals have some input. Few more things... 1) The fines box was never close to being full during any of the cleanings. MAYBE 1/3 at MOST. 2) It clunks with no pellets or fines anywhere in the system UNTIL I hit that unknown magic spot with my tapping method, at which point it's quiet again. 3) I highly doubt it's the pellets. They were never wet/damp and don't feel crumbly in any way, they're not unusually long or short, nor do they contain excessive fines. 4) I tried putting a little powdered graphite on the edges of the slide plate and working it in, to no avail. So, any ideas?